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EP3812061A1 - Verfahren zur herstellung eines vorsprungteils, system zur herstellung eines vorsprungteils und verfahren zur herstellung einer metallkomponente mit dem vorsprungsteil - Google Patents

Verfahren zur herstellung eines vorsprungteils, system zur herstellung eines vorsprungteils und verfahren zur herstellung einer metallkomponente mit dem vorsprungsteil Download PDF

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Publication number
EP3812061A1
EP3812061A1 EP19810837.5A EP19810837A EP3812061A1 EP 3812061 A1 EP3812061 A1 EP 3812061A1 EP 19810837 A EP19810837 A EP 19810837A EP 3812061 A1 EP3812061 A1 EP 3812061A1
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EP
European Patent Office
Prior art keywords
protrusions
metal
forming
pressing
die
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP19810837.5A
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English (en)
French (fr)
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EP3812061B1 (de
EP3812061C0 (de
EP3812061A4 (de
Inventor
Masakatsu SEKI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Seki Press Co Ltd
Original Assignee
Seki Press Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Publication of EP3812061A1 publication Critical patent/EP3812061A1/de
Publication of EP3812061A4 publication Critical patent/EP3812061A4/de
Application granted granted Critical
Publication of EP3812061B1 publication Critical patent/EP3812061B1/de
Publication of EP3812061C0 publication Critical patent/EP3812061C0/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/08—Upsetting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/02—Stamping using rigid devices or tools
    • B21D22/06—Stamping using rigid devices or tools having relatively-movable die parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/20—Making uncoated products by backward extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/02—Stamping using rigid devices or tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J13/00—Details of machines for forging, pressing, or hammering
    • B21J13/02—Dies or mountings therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/44—Making machine elements bolts, studs, or the like
    • B21K1/46—Making machine elements bolts, studs, or the like with heads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/76—Making machine elements elements not mentioned in one of the preceding groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K23/00—Making other articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B11/00—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses
    • B30B11/007—Presses specially adapted for forming shaped articles from material in particulate or plastic state, e.g. briquetting presses, tabletting presses using a plurality of pressing members working in different directions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B13/00—Methods of pressing not special to the use of presses of any one of the preceding main groups

Definitions

  • the present invention relates to a method for forming protrusions, a system for forming protrusions, and a method for manufacturing a metal component having the protrusions, in which the protrusions can be easily formed by press molding without making a metal plate thinner or without reducing the diameter of a metal plate, in relation of metal plates or metals rod having protrusions to be used for components or current collecting terminals of various devices, and so on.
  • the method for forming protrusions by press molding according to the above (1) is applied not only to inertial arms for HDD disclosed in Patent Document 1, but also to embossed molded products, heat radiating plates, current collecting terminals, and so on, resulting in a highly versatile technology with a wide range of applications.
  • the method according to the above (1) is applied in combination with post-processing in which the back surface or the formed surface of a protrusion is cut or polished in order to flatten one surface of a metal plate after protruding the protrusion by press forming (see Patent Documents 2 and 3).
  • a method of forming a truncated cone-shaped protrusion in which the wall thickness of a tip portion is thicker than that of an outer peripheral wall is also proposed by combining the method disclosed in the Patent Document (1) with the pre-process of squeezing by a press. (See Patent Document 4)
  • Patent Document 5 discloses a method for forming protrusions in which a part of the metal plate is pushed into a recessed part by performing a press working, wherein a pressing die having the protrusion-shaped recess is pressed against the metal plate.
  • Patent Document 6 proposes a method for forming protrusions, the method comprising: fitting a second die to a first die having a cavity with a protrusion part by sliding the second die to match the cavity of the first die; moving the second die toward the first die; and filling and molding a metal material between the cavity of the first die and the second die.
  • Patent Document 7 proposes a method for forming protrusions, the method comprising: pressing two adjacent positions on one surface of a metal workpiece; forming metal flow portions in opposite directions between the two adjacent positions; and forming raised portions (protruding portions) of the metal workpiece.
  • Patent Document 8 discloses a method for forming a hollow shaft with protrusions by a hydraulic bulge processing, in which a die is slid in the axial direction of a metal base tube while injecting a processing liquid inside the metal base tube.
  • Patent Documents 9 and 10 a method for manufacturing a press-molded product by forming thick portions on a metal flat plate member and a molding device thereof have also been proposed (for example, Patent Documents 9 and 10).
  • the flat plate part of the metal flat plate member is pressed by bringing a first press portion and a second press portion closer to each other, wherein the first press portion faces the first end of the flat plate portion and the second press portion faces the second end that is located in a opposite side to the first end.
  • the press forming method is a technique that has been conventionally useful as a method for forming protrusions, because the press forming method has several advantages, such as formation of high-quality protrusions, a suitable applicability to precision metal parts, a simplified process of forming protrusions, the low cost production, and so on.
  • Patent Documents 1 to 10 the conventional methods for forming protrusions or thick-walled portions have the following technical problems, as disclosed in Patent Documents 1 to 10. That is, the methods disclosed in Patent Documents 1 to 4 have problems that solid protrusions cannot be formed, that it is difficult to form high-quality protrusions because it is likely to occur cracks or breaks in protrusions or their peripheral portions in the case of a thin metal plate or a metal rod having a small diameter, and that the process becomes complicated because the post-process such as cutting, polishing, or so on is required.
  • Patent Documents 5 and 6 also have the following problems when applying the methods to a thin metal plate and a metal rod, respectively.
  • the application of the methods to the thin metal plate is difficult, because the main body thickness of the thin metal plate becomes thinner after forming the protrusions.
  • it is difficult to press the metal rod uniformly by a press forming and not only is the height of the protrusions greatly restricted, but it is also likely to generate a local deformation in the body part of the metal rod after formation of the protrusions.
  • the method disclosed in Patent Document 7 has a poor degree of freedom in selecting the shape of the protrusions, since the formed protrusions are limited to an annular shape, and more may cause an appearance problem that dents may be generated on the surface of the metal body (the surface on which the protrusions are formed) after a processing. Further, if the protrusions are to be formed highly, the dents seen on the metal surface after the processing become large, which may adversely affect the strength of the protrusions and the metal body. From the above, the method disclosed in Patent Document 7 is not suitable for application to metal parts requiring high quality or high precision protrusions, for example, current collecting terminals.
  • Patent Document 8 fails to describe and suggest a method for forming protrusions on one surface of a metal plate or a metal tube. It cannot be said that the invention of the Patent Document 8 is one that recognizes such the method.
  • the methods disclosed in the Patent Documents 9 and 10 are ones for forming a thick-walled portion on a metal flat plate member, in which the thick-walled portions (the thickened portions) are generally formed in a low shape having the size that the protrusion height from the metal flat plate member is smaller than the thickness of the metal flat plate member.
  • the method for forming thickened forming portions only a heat or warm working (hot pressing) for forging, or a press forming by heating a metal flat plate member as a whole or locally, is available. A cold working has only been suggested therein.
  • Patent Document 9 discloses the press forming method, in which a first press portion facing the first end of the flat plate portion is slid together with a second press portion facing a second end located in an opposite side to the first end.
  • the height of the thickened portion that can be formed was limited, since a slidable distance and an applicable press pressure during molding were restricted.
  • Objects of the present invention are to provide a method for forming protrusions and a system for forming protrusions, in which the solid protrusions can be easily formed at a temperature lower than a softening point of a metal used as the metal workpiece by press molding without thinning a metal plate or reducing the diameter of a metal rod, in relation to metal plates or a metal rods having protrusions to be used for parts of various devices, current collecting terminals, and so on.
  • Another object of the present invention is to provide a method for manufacturing a metal part having protrusions formed by the method for forming protrusions.
  • the present invention has been made according to the present inventor's finding that the above-mentioned problems can be solved by adopting a method, comprising: pressing a cross section of an outer peripheral end part of each workpiece from the horizontal direction, not from a vertical direction, to the upper and lower surfaces of a metal plate used as a workpiece, or a longitudinal direction of a metal rod used as the workpiece; and undergoing plastic flows into one or more through-holes formed as recessed parts that serve as female molds for forming the protrusions.
  • the configuration of the present invention is as follows.
  • solid protrusions can be easily formed without making a metal plate thinner or reducing the diameter of a metal rod, in relation to metal plates or metal rods having protrusions to be used for components or current collecting terminals of various devices, and so on.
  • solid protrusions can be easily formed higher than the thickness of a metal plate or the diameter of a metal rod, wherein the metal plate or the metal rod is used as the work.
  • the present invention has an advantage that the cutting or polishing process can be performed in a short time, as compared with the conventional extrusion method by a press forming.
  • the method for forming protrusions according to the present invention can easily form not only the protrusions with a high quality, due to formation of the solid protrusions having high uniformity and high strength in comparison with the conventional extrusion molding method of powder metal or the molding method of semi-molten metal, but also two or more protrusions at desired positions on the metal workpiece.
  • the metal workpiece is a metal plate
  • the protrusions can be formed not only on the upper and lower surfaces of the metal plate but also on both side surfaces.
  • the protrusions can also be formed in not only a conical shape but also a pyramidal shape. Thus, it is possible to widen the range for selecting a direction (an angle) at which the protrusion is formed and a shape of the protrusion.
  • the method for forming protrusions according to the present invention can be performed at a lower molding temperature when forming the protrusions, as compared with the conventional method of molding semi-molten metal.
  • the specific molding temperature in the present invention is lower than the softening point of a metal material used as the workpiece, and it is possible to form the solid protrusions having a uniform shape even in the molding at room temperature.
  • a system for forming protrusions to according to the present invention does not need to use an additional device such as a heating device and so on, since the system has a simple structure including a mold, a presser mold, a clamping device and a press molding machine, whereas the method of molding semi-molten metal needs to perform complicated managements such as injection molding conditions and so on by using a special molding apparatus such as a metal injection molding device.
  • a special molding apparatus such as a metal injection molding device.
  • To control and manage the press molding conditions and so on in the present invention is also easier than when using the metal injection molding apparatus. Therefore, the manufacturing cost for forming the protrusions can be significantly reduced, as compared with the conventional method of molding semi-molten metal.
  • the method for manufacturing a metal component according to the present invention can not only form one or a plurality of solid protrusions with high strength at arbitrary positions, but also provide metal components having various shapes and functions by combining with the conventional process of the press extrusion molding, or the press pressing molding in which another pressure die having the recessed parts is pressed on the working surface.
  • the present invention enables its application to expand not only to general-purpose metal components but also to precision metal components, since it can be applied to metal components having a thin metal plate or a small diameter metal rod as a main body.
  • FIGS. 1A to 1D illustrate diagrams for explaining process outlines of a method for forming protrusions according to the present invention.
  • a cross-sectional view of each process is shown on the left side, and a perspective view of a metal plate used as an example of a metal workpiece is shown on the right side before and after the process of forming a protrusion.
  • the method for forming protrusions according to the present invention will be explained by FIGS. 1A to 1D .
  • a workpiece 1 of a metal plate is inserted between a support die 2 for supporting the work 1 and a pressure die 3 for holding the workpiece 1 (see FIG. 1A ).
  • the support die 2 and the pressure die 3 are clamped in the direction of the arrow to fix the workpiece1 (see FIG. 1B ).
  • the pressure die 3 has a recessed part that serves as a female mold for a protrusion to be formed.
  • a through-hole 4 is formed in the same diameter as the opening of the recessed part.
  • the recessed part of the pressure die 3 may be formed in a configuration of inserting a knockout pin into the through-hole 4.
  • a non-penetrating part having a shape equal to or longer than the height of a protrusion to be formed may be formed as the recessed part, but an application of the non-penetrating portion is limited to formation of a low protrusion.
  • the outer peripheral end part 5 of the workpiece 1 is pressed by press forming using a pressing die furnished in a press forming machine, or a pressing jig (not shown) such as a pressing punch and a pressing plunger, and the metal is plastically flowed from the two directions on both sides of cross sections of the outer peripheral end parts 5 of the workpiece 1 toward the through-hole 4.
  • the metal flowed inside the through-hole 4 by the plastic flow forms the protrusion 6.
  • the height of the protrusion 6 can be controlled by adjusting the pressing force, pressing speed, and pressing time in the press forming.
  • the press forming it is practical to perform the press forming by setting the press load and the press load speed in the range of 1 to 50 tons and 0.1 to 50 mm / sec, respectively.
  • the range of 1 to 10 tons and 1 to 10 mm / sec may be used, respectively.
  • the pressure die 3 requires a high clamping pressure in order to suppress a lifting of the workpiece 1 when pressed by the press forming.
  • the clamping pressure may be continuously applied with a high value set from the beginning of the pressing process.
  • the clamping pressure of the pressing die 3 is 10 tons or more, preferably 30 tons or more, and more preferably 50 tons or more in order to suppress the lifting of the workpiece 1.
  • the upper limit of the clamping pressure is not particularly limited, but 200 tons or less is practical from the viewpoint of the capacity of the press molding machine and the life of the pressure die and the support die.
  • the clamp pressure is released, the pressure die 3 is demolded in the direction of the arrow ( ⁇ ), and then the workpiece 1 having the protrusion 6 is taken out.
  • On the back surface of the formed solid protrusion only a trace after the plastic flow of metal generated by the press molding are seen as a small residual recessed part, and a substantially flat back surface is formed.
  • the trace portion is cut into slices or only the trace portion is polished.
  • the workpiece 1 on which the protrusion 6 are formed in this way is processed into a desired metal part by removing unnecessary portions from the main body portion of the workpiece by post-processing such as punching or cutting.
  • the method for forming protrusions according to the present invention can form the solid protrusion by pressing the cross sections 5 of the outer peripheral end part of workpiece 1 by the press molding from a direction perpendicular to the upright direction of the protrusion 6 when the protrusion 6 to be formed on the metal workpiece 1 is viewed as a reference position, and by plastically flowing the metal of the workpiece 1 inside a through-hole formed as a recessed part that serves as a female mold for forming the protrusion 6.
  • the present invention is characterized in that the pressing is performed against each cross section 5 of the outer peripheral end parts of workpiece 1 from a direction parallel to the surface of the workpiece 1.
  • the present invention is also different from the method for forming a thick portion, as disclosed in Patent Document 9 or 10.
  • the through-hole is formed as the recessed part of the pressure die 3, and each cross sections 5 of the outer peripheral end parts of workpiece 1 is press molded by using the pressing die or a pressing jig that is furnished separately from the support die 2 and the pressing die 3.
  • the workpiece used in the present invention is not limited to the rectangular metal plate as shown in FIGS. 1A to 1D .
  • the workpiece may be a metal plate having any shape of a disk, an ellipse, and a polygon having three or more sides, or a metal rod or a flat metal having a cross-sectional shape of a circle, an ellipse, and three or more polygons.
  • a metal plate is used as the workpiece, it is not particularly necessary to use a plate-like material having a thickness equal to or greater than the total thickness of the metal body portion and the protrusion, differing from the invention disclosed in Patent Document 1.
  • a thin strip material having a thickness of less than 5 mm may be used.
  • a thick strip material of several tens of mm or more can be also used.
  • the thickness of the applicable metal plate is determined by the capacity of the press molding machine used.
  • a rod-shaped material having a small diameter of less than 0.5 mm to a large diameter of several tens of mm or more can be used as in the case of the metal plate.
  • the metal material to be a workpiece not only metal materials having excellent press formability such as aluminum, aluminum alloy, copper, low carbon steel, magnesium and so on, but also metal materials having poor press formability such as high carbon steel, phosphor bronze, stainless steel, titanium and so on can be used if the press forming is possible.
  • the present invention performed by pressing the cross section 5 of the outer peripheral end part of the workpiece 1 by the press molding can be applied by examining and optimizing molding conditions as long as the metal can plastically flow.
  • the protrusion is formed on one surface of the metal plate by pressing the metal plate from the peripheral end parts thereof with a pressing die or a pressing jig that is furnished in a press forming machine, while clamping and fixing the metal plate with the pressure die and the support die from above and below of the metal plate.
  • the pressing die or the pressing jig is furnished in the press forming machine as a different configuration from the support die and the pressure die.
  • the positions where the support die and the pressure die are installed are relative to each other, and both dies may be installed at opposite positions.
  • the parts that come into contact with the metal rod in the pressure die and the support die are curved along the outer peripheral shape of the metal rod, and a recessed part that serves as a female mold for forming the protrusion is formed into the pressure die.
  • the entire outer peripheral surface of the metal rod is considered as one surface of the workpiece.
  • the pressing by the pressing die or the pressing jig furnished in the press forming machine is performed from each cross section of both end parts of the metal rod.
  • the positions where the support die and the support die for clamping the metal rod are installed are relative to each other, and both dies may be arranged in reverse in the case of the metal plate.
  • the protrusion 6 can be formed not only in the direction perpendicular to the metal plate of the workpiece 1 but also in the oblique direction thereto.
  • the through-hole 4 corresponding to the recessed part may be formed so as to be inclined in an oblique direction against the clamping plane of the pressure die 3.
  • the hollow protrusion formed by extrusion in the oblique direction easily cause cracks and breaks during the process, and the wall surface thickness tends to be uneven, which causes quality problems sometimes.
  • the present invention does not need to perform such a complicated process. In the present invention, not only can the protrusions in the oblique direction be easily formed by a simple process, but the quality of the protrusions can be also improved.
  • the method for forming protrusions according to the present invention can form the protrusions having various shapes, including not only a conical shape but also a pyramid shape as a protrusion shape.
  • the pyramidal protrusion it can be easily formed only by making a cross-sectional shape of a recessed part of the pressure die 3 polygonal.
  • the height of the protrusion can be adjusted only by changing the press forming conditions. Since the pyramidal protrusion formed in this way has a solid structure, it becomes a high-strength protrusion with high uniformity, as compared with the hollow structure obtained by the conventional extrusion method.
  • the workpiece 1 is a rectangular metal plate, and the pressing direction by press forming is two directions.
  • the pressing directions are not limited to two directions, and may be three or more directions.
  • the pressing direction by press forming may be from circumferential directions of the bottom surface of the protrusion to be formed.
  • the pressing direction by press forming may be from circumferential directions of the bottom surface of the protrusion to be formed.
  • the present invention may use a work in which the portion supporting the protrusion 6 and the portions reduced in length by the pressing may be separated.
  • FIGS. 2A to 2C show examples of metal workpieces in which portions supporting protrusions and portions reduced in length by pressing are separated.
  • FIGS. 2A to 2C show metal workpieces made of plate-shaped metal plates, and illustrate the shapes of the metal plates when viewed from the back surfaces.
  • the bottom surface of the protrusion to be formed is represented by a circularly dotted line as each example of metal workpieces.
  • the press forming is performed from two directions or four directions that are different from a longitudinal direction of the workpiece 7 or 10, or from circumferential directions around the bottom surface of the protrusion formed on the workpiece 12..
  • the metal plate workpiece 7 When the pressing is performed from two directions, the metal plate workpiece 7 has a part 8 supporting the protrusion to be formed, and 9a and 9b as the parts 9 pressed by press forming ( FIG. 2A ).
  • the metal plate workpiece 10 When the pressing is performed from four directions, the metal plate workpiece 10 has the part 8 supporting the protrusion to be formed, and 11a, 11b, 11c, and 11d as the parts 11 pressed by press molding ( FIG. 2B ).
  • the metal plate workpiece 12 When the pressing is performed from the circumferential directions, the metal plate workpiece 12 has the part 8 supporting the protrusion to be formed, and peripheral parts 13 pressed by press forming ( FIG. 2C ).
  • the parts 9, 11 and 13 pressed by press forming in the metal plate workpieces 7, 10 and 12 are the shapes extending in two or more directions that are point-symmetrical, when the center of the bottom surface of each protrusion to be formed is a symmetrical center.
  • the extending metal parts 9, 11 and 13 can be cut or polished to a desired length after the protrusions are formed and used as the main body part of the metal component. If necessary, the part 8 supporting the protrusion may also be cut or polished to a desired length at the same time.
  • the extending metal parts are not limited to the two directions, four directions and the circumferential direction, as shown in FIGS. 2A to 2C , and may be formed in a plurality of directions including an even number of 6 or more or an odd number of 3 or more.
  • a shape extending in two or more directions as a part of the workpiece pressed by press forming can be formed, based on the same concept as the metal plates shown in FIGS 2A to 2C .
  • the protrusion formed on the metal plate is not limited to only one surface of the metal plate, and may be formed on one or more side surfaces thereof. Further, two or more protrusions may be formed on both top and bottom, or both sides of the metal plate. Also in the case of a metal rod, a plurality of protrusions can be formed at two or more arbitrary positions on the entire outer circumference thereof. A method of forming a plurality of protrusions on a metal plate or a metal rod will be described in detail in the embodiments described later.
  • the present invention is a method in which, when solid protrusions are formed on one surface of the work, the pressing by press molding can be performed at a temperature lower than a softening point of a metal material used as the workpiece. This is because the plastic flow of metal generated by the pressing is used when forming the solid protrusions.
  • the pressing by press forming is practically performed at room temperature in order to eliminate complicated operations such as temperature control.
  • As a method for forming solid protrusions that is different from the present invention has been conventionally proposed, for example, the method for forming protrusions by injection molding a metal in a semi-molten state heated above the softening point.
  • the metal injection molding method not only requires the use of a special metal injection molding apparatus, but also involves complicated works for adjusting the temperature at the time of molding and setting the molding conditions.
  • the present invention simplifies the process because it is not necessary to use a special molding apparatus and it is possible to form more high protrusions without controlling the molding temperature.
  • the method according to the present invention can also reduce the manufacturing cost.
  • the present invention has an advantage of easily forming high protrusions at room temperature, as compared with the method for forming thick portions, as disclosed in Patent Documents 9 and 10.
  • FIG. 3 illustrates a cross-sectional view showing a schematic configuration of a system for forming protrusions according to the present invention.
  • a system for forming protrusions 14 according to the present invention fundamentally comprises: a support die 2 for supporting a metal workpiece; a through-hole 4 corresponding to a recessed part serving as a female mold for the protrusion to be formed on one surface of the workpiece 1; a pressure die 3 for suppressing a lifting of the workpiece; a clamping device((not shown) having clamping plates 15 for clamping the support die and the pressure die; and a press molding machine 16 for pressing each cross section of the outer peripheral end parts of the workpiece 1.
  • the press molding machine 16 shown in FIG. 3 is a machine example having two pressing dies 17 which are furnished as an example of a pressing die or a pressing jig in order to press from two directions of each cross section of the outer peripheral end parts of the workpiece 1.
  • three or more pressing dies may be furnished depending on the shape of the workpiece 1 and the pressing directions on the workpiece 1.
  • the pressing die or the pressing jig is not limited to the pressing dies 17 shown in FIG. 3 .
  • a pressing jig such as a pressing punch and a pressing plunger can be used.
  • a small-diameter air vent-hole 18 connected to the through hole 4 of the holding die 3 is formed in the upper clamping plate 15.
  • the air vent-hole 18 is formed to avoid a large pressure increase that occurs when a part of the metal enters the inside of the through-hole 4 by a plastic flow of metal when the protrusion is formed.
  • the air vent-hole 18 may not be formed. In that case, the pressure die 3 may be provided with a recessed part of a non-through hole instead of the through-hole 4.
  • the through-hole 4 is therefore suitable as the recessed part.
  • FIG. 4 illustrates a cross-sectional view showing a modified example of the system for forming protrusions according to the present invention.
  • a press forming machine 16 has a cam mechanism for converting a pressing force acting in a direction perpendicular to the clamp surface 15 of the pressure die 3 to a force acting in a direction parallel thereto through the pressing die or the pressing jig.
  • a cam with a function that can change an amount of movement can be used.
  • the cam comprises: a cam drives 20; and a cam slides 21 functioning as the pressing die or the pressing jig.
  • the slopes of the cam drives 20 and the cam slides 21 are always in contact with each other, and the cam slides 21 also moves in a horizontal direction in proportion to a vertical movement of the cam drives 20.
  • the system for forming protrusions according to the present invention not only makes the cam slides 21 function as the pressing die or the pressing jig, but also may adopt a configuration in which the pressing is performed toward each cross section of the outer peripheral end parts of the workpiece by a movement of the pressing die (for example, the pressing die 17 shown in FIG. 3 ) or a pressing jig accompanying a drive of the cam slide 21, wherein the pressing die or the pressing jig is arranged separately between the cam slide 21 and the cross section of the outer peripheral end part of the workpiece.
  • a cam having a constant movable amount may be used instead of the cam having a variable movable amount.
  • a method of pushing a cylindrical cam drive into the cam slide to move the cam slide horizontally, or a method of using a cam having a return mechanism may be adopted.
  • the system for forming protrusions having the cam mechanism shown in FIG. 4 , can collectively control the pressing of the press molding machine, the device configuration of the system can be simplified and the device itself can be made compact, as compared with the system shown in FIG. 3 , in which the pressing is controlled in a distributed manner by the independent press molding machine.
  • the effect obtained by the system 19 is enhanced when the cross sections of the outer peripheral end parts of the workpiece 1 are pressed from three or more directions.
  • the system shown in FIG. 4 has a knockout pin 22 to be inserted into the through-hole 4 of the support die 3.
  • the knockout pin 22 does not have to be furnished, but when the height of the protrusion to be formed is adjusted or the head of the formed solid protrusion requires a precise structure, the use of knockout pins 2 simplifies their control.
  • the metal workpiece having the solid protrusions formed as described above is processed into the desired metal component by removing unnecessary portions from the main body of the metal workpiece by post-processing such as punching or cutting. Since the portion pressed by press molding leaves traces generated by the pressing after the protrusions are formed by press molding, it is necessary to remove these traces as unnecessary portions.
  • the traces after the pressing are thin metal pieces that tend to remain around the reduced portion at each cross section 5 of outer peripheral end parts of the metal workpiece, that is, in the boundary between the support die and the pressure die after the process shown in FIG. 1C . Even when the metal extending parts 9, 11 and 13 are provided as the pressed portions on the workpieces 7, 10 and 12, as shown in FIGS.
  • the metal portions remaining without fitting into the desired size after being pressed by press forming are also removed by post-processing such as punching or cutting. Finally, the punching or the cutting is performed to process to the optimum component size when used as a metal component.
  • the present invention changes the shape and the structure of protrusions from the viewpoint of strength, function and design when manufacturing a metal component having protrusions with a higher height, or forming truncated cone-shaped protrusions so that the wall thickness of the protrusion tips is thicker than that of the outer peripheral wall
  • a process of extruding the back surfaces of the solid protrusions by press molding may be continued after the process of forming the protrusions according to the present invention.
  • the pressing may be performed against the surface of the workpiece after the formation of protrusions by using another pressure die having protrusion-shaped recessed parts.
  • the method for manufacturing a metal component according to the present invention may include a process of polishing or cutting the back surface of the portion involving the protrusions, after the process of forming solid metal protrusions.
  • this process of polishing or cutting is performed to form a flat back surface by eliminating the traces. In that case, only the trace portions may be cut in a slice shape or may be polished, but not the entire metal part.
  • the polishing process or the cutting process may be performed before or after any of those processes.
  • the polishing process or the cutting process can also be performed before or after any of the processes above.
  • the method for manufacturing a metal component having protrusions according to the present invention, at least any of processes including (a) punching or the cutting for processing the metal workpiece to an optimum part size, (b) the press extrusion molding or press pressing molding for changing the shape and structure of the protrusions, and (c) polishing or cutting for flattening the back surfaces of the protrusions are performed in combination with the process of forming the solid metal protrusions, if necessary.
  • the process of forming the solid metal protrusions and at least any of the processes including (a), (b), and (c) above may be performed separately as an independent process, or as a continuous process by a progressive method or a transfer method.
  • the automation of the line becomes easy, and the metal component having the protrusions can be manufactured efficiently and with stable quality. Thereby, it is possible to provide a high quality metal component at low cost.
  • the manufacturing method according to the present invention can be applied to various metal components.
  • a large effect can be obtained by the present invention when applied to a method for manufacturing a current collecting terminal that requires at least one of a high strength, a high protrusion shape, a good electrical conductivity.
  • the present invention can be applied to applications such as storage batteries, connectors, and wiring connections used for applications of electrical and electronic parts, transportation equipment such as automobiles, and industrial equipment such as machine tools.
  • the present embodiment will explain a method for forming protrusions that is performed according to the processes shown in FIG. 1 using a metal plate of C1100-1 / 4 series copper having a thickness of 1.5 mm as a workpiece 1.
  • the copper plate workpiece before forming a protrusion had the same shape as shown in FIG. 2B ,
  • the copper plate having four portions pressed by press molding was used, wherein the four portions extend in four laterally oblique directions located point-symmetrically with respect to the part supporting the protrusion when the center of the bottom surface of a formed protrusion is a symmetrical center.
  • a protrusion was formed according to the following processes: (a) inserting the workpiece 1 of the copper plate having the above shape between a support die 2 and a pressure die 3; (b) clamping the workpiece 1 by the support die 2 and the pressure die 3; (c) forming the protrusion 6 by pressing each cross section of the outer peripheral end parts of the workpiece 1 having four extending portions to be pressed from the four directions of the extending portions with a pressing die or a pressing jig by press molding using a press forming machine, and undergoing a plastic flow of metal into a through-hole 4 corresponding to a recessed part of the pressure die 3; and (d) releasing the clamping pressure and taking out the workpiece 1 having the formed protrusion 6 in the state where the pressure die was removed.
  • a servo press machine having a cam mechanism at four places to be pressed was used as the press forming machine, wherein the servo press machine had a configuration of pressing cam slides 21 intermittently by making the cam slides 21 function as the pressing die or the pressing jig.
  • the pressing process by press forming was performed at room temperature without heating the copper plate of the workpiece 1.
  • the clamp pressure of the pressure die 3 was set to 10 tons immediately after press forming, and then gradually increased with the pressing time, and set to 80 tons at the end of pressing.
  • the workpiece 1 having the formed the protrusion was processed into a circular shape by cutting the portions extending in four directions and around the protrusion.
  • FIGS. 5A and 5B show the appearance and the cross section of the copper plate having the protrusion 23 formed by this method, respectively.
  • FIG. 5A and 5B are the photographic views showing the appearance and cross section of the copper plate, respectively.
  • the solid protrusion 23 having the height of 7 mm or more was formed on one surface of the copper plate.
  • no cracks or so on were observed in the cross section of the solid protrusion 23. It can be understood that the pressing was performed smoothly in the pressing process of the protrusion forming method (the process shown in FIG. 1C ). Almost no trace of the plastic flow of metal generated by press molding is observed on the bottom surface of the solid protrusion 23.
  • the substantially flat back surface is formed.
  • no initial grain boundary, no deformation band, and no macroscopic structure were observed at the tip, the rising portion, and the bottom of the protrusion.
  • the present embodiment confirms that the solid-shaped protrusion 23 with the uniform refinement of metal crystal grains was formed in a high shape having a size larger than the thickness of the copper plate (1.5 mm).
  • an A5052-H32 series aluminum plate was used, and a protrusion was formed on one surface of the aluminum plate in the same manner as in the first embodiment.
  • the shape of the aluminum plate before forming the protrusions is also the same as that of the copper plate in the first embodiment.
  • FIGS. 6A and 6B show photographic views showing the appearance and the cross section of the aluminum plate having the formed solid protrusion 24, respectively.
  • the solid protrusion 24 having the height of 7 mm or more was formed on one surface of the aluminum plate.
  • FIG. 6B no cracks or so on are observed in the cross section of the protrusion 24, and it can be seen that the pressing process in the method for forming protrusions (the process shown in FIG. 1C ) was smoothly performed in the same way as that of the copper plate of the first embodiment.
  • a slight depression (recessed part) 25 which is a trace of the plastic flow of metal generated by the press forming, was observed on the bottom surface of the solid protrusion 24.
  • the solid protrusion with the uniform refinement of the metal crystal grains is formed in the high shape having a size larger than the thickness (1.5 mm) of the aluminum plate.
  • FIGS. 7A to 7D illustrate diagrams for explaining process outlines for forming a protrusion using a metal rod with a circular cross-sectional shape as a workpiece in the present embodiment.
  • the cross-sectional view of each process is shown on each left side of FIGS. 7A to 7D .
  • FIGS. 7A and 7D perspective views of the metal rod used as an example of the metal workpiece are shown before and after the process of forming the protrusion, respectively.
  • FIGS. 7B and 7C show cross-sectional views taken along A-A line and B-B line in each process.
  • a protrusion forming method when forming a protrusion on one surface of a metal rod will be described by FIGS. 7A to 7D .
  • a protrusion was formed according to the following processes: (a) inserting a workpiece 26 of the metal rod between a support die 27 and a pressure die 28; (b) clamping the workpiece 26 with the support die 27 having a circular cross section that follows a cross-sectional shape of the workpiece 26, and a pressure die 28; (c) forming a protrusion 31 by pressing each cross section 30 of the outer peripheral end parts of the workpiece 26 from two directions of the workpiece 26 to be formed with a pressing die or a pressing jig (not shown) by press molding using a press forming machine, and undergoing a plastic flow of metal into a through-hole 29 corresponding to a recessed part of the pressure die 28; and (d) releasing the clamping pressure, removing the pressure die, and taking out the workpiece 26 of the metal rod on which the protrusions are formed.
  • the protrusion 31 without cracks or chips can be formed on the workpiece 26
  • FIGS. 8A to 8D illustrate diagrams showing processes of forming a diagonal protrusion on a metal plate workpiece in the present embodiment of the present invention.
  • a cross-sectional view of each step is shown on the left side, and perspective view of a metal plate used as an example of a metal workpiece are shown on each right side before and after each process of forming the protrusion.
  • a method of forming protrusions in which the protrusion is formed obliquely against one surface of the metal plate will be explained by FIGS. 8A to 8D .
  • the support die 33 and the pressure die 34 are clamped in the directions of the arrows (in FIG. 8B ).
  • the pressure die 34 has a through-hole 35 formed in an oblique direction against one surface of the workpiece 32 in accordance with the direction of the protrusion to be formed, and a knockout pin 36 inserted into the through-hole 35.
  • the protrusion is formed in the oblique direction by pressing each cross section 37 of outer peripheral end parts of the workpiece 32 from a plurality of directions of the outer peripheral end parts of the workpiece 32 to be pressed with a pressing die or a pressing jig (not shown) using a press forming machine, and by undergoing a plastic flow of metal into the through-hole 35 corresponding to a recessed part of the pressure die 34.
  • a sudden increase in pressure can be suppressed by gradually moving the knockout pin 36 upward of the pressure die 34, since the internal pressure of the through-hole 35 increases with the formation of the protrusion 38.
  • the clamp pressure is released and the knockout pin 36 is moved below the pressing die 38 to eject the pressing die 34 from the workpiece 32 while protruding the head of the protrusion 38. Then, the metal plate workpiece 32 on which the protrusion 38 is formed is taken out.
  • the protrusion 38 is formed in the oblique direction against one surface of the workpiece 32 of the metal rod.
  • the oblique protrusion 38 formed by the present embodiment can be formed only by filling the through-hole 35 corresponding to the recessed part of the pressure die 34 with the plastic flow of metal. Therefore, the uniformity of the internal metal structure is good, and it is possible to form the protrusion 38 without cracks or chips in appearance.
  • FIGS 9A and 9B a method for forming a plurality of protrusions on a metal plate or a metal rod used as a workpiece will be explained by FIGS 9A and 9B .
  • FIG. 9A is a diagram showing a process of simultaneously forming protrusions 42 and 43 at different positions on one surface of a workpiece 41 of the metal plate clamped by a support die 39 and a pressure die 40.
  • FIG. 9B is a diagram showing a process of forming protrusions 47 and 48 at different positions on both sides of a workpiece 46 of the metal plate clamped by a support die 44 and a pressure die 45.
  • FIG. 9C is a diagram showing a process of forming protrusions 52 and 53 at the same positions on both sides of a workpiece 51 of the metal plate clamped by a support die 49 and a pressure die 50.
  • a photographic view of one protrusion appearance in the protrusions 52 and 53 formed in the process shown in FIG. 9C is also shown in FIG. 9D .
  • FIGS. 9A, 9B, and 9C shows each of shapes of the metal plate workpieces 41, 46, and 51 when viewed from the back surface.
  • Each of the shapes has a supporting portion for supporting the protrusions to be formed and portions extending from the supporting portion in two horizontal and vertical directions or four horizontal and diagonal directions.
  • FIGS. 9A, 9B, and 9C show the portions pressed by press molding from four directions indicated by arrows.
  • the circular dotted line shown in the lower part of each drawing of FIGS. 9A to 9C schematically represents the bottom surfaces of the two protrusions to be formed.
  • the portions extending in the two horizontal and vertical directions or the four horizontal and diagonal directions are formed along the pressing direction of the press forming.
  • the metal thinning is observed in the pressing direction, since each cross sections of the end portions of the extended portions moves to the forming position of the protrusions due to the plastic flow of metal.
  • the protrusions 42 and 43 are formed by the plastic flows of metal portions extending in two horizontal and vertical directions (two vertical directions in the drawing) from the positions of the protrusions 42 and 43, respectively.
  • two protrusions can be formed on one surface of the metal plate workpiece 41 by the same method as the processes shown in FIGS. 1A to 1D , since two through-holes are formed in the pressure die 40.
  • one through-hole is formed in the support die 44 and the pressure die 45, respectively.
  • the two protrusions 47 and 48 are formed in two directions (horizontal and vertical directions) from the positions of the protrusions 47 and 48, respectively.
  • one protrusion is respectively formed at a different position on both sides of the metal plate workpiece 46 by the plastic flow of metal parts extending in two horizontal and vertical directions (two upper and lower directions in the drawing) of the metal piece, and thereby a total of two protrusions are formed.
  • one through-hole is formed in the support die 49 and the pressure die 50, respectively.
  • One protrusion is respectively formed on each of both sides of the metal plate workpiece 51 by each plastic flow of the metal portions extending in four laterally oblique directions (four diagonally up and down directions in the drawing), since the protrusions 52 and 53 are at the same position.
  • a total of two protrusions 52 and 53 facing the same position have the height shape having a size larger than the thickness of the metal plate workpiece 51.
  • the plurality of solid protrusions are formed at desired positions on one or both sides of the metal plate workpiece.
  • the plurality of protrusions formed by the present embodiment can be formed simply by filling the metal into the through-holes or the recessed parts corresponding to the through-holes, formed in at least each of the support die and the pressure die, by the plastic flow of metal, wherein the recessed parts serve as female molds for forming the protrusions. Thereby, the plurality of protrusions can be easily formed.
  • the method for forming two protrusions on one or both sides of the metal plate workpiece has been described as an example, but the number of protrusions to be formed may be three or more. Further, when forming the metal portions extending in the horizontal vertical direction or the horizontal diagonal direction from the protrusion position, the most suitable ones can be selected by engineers within the scope of design items, regarding the arrangement angle and the number of arrangements, and the length and width of the extended metal portions. As a result, it is possible to form the plurality of protrusions two-dimensionally not only in one row but also in two or more rows.
  • the plurality of protrusions can be formed anywhere on the metal rod by optimizing the structure of the pressure die and the support die, and the shape and dimension of the recessed parts formed in each die.
  • FIGS. 10A to 10D A pressing process by press molding when forming a plurality of protrusions on one side of side surfaces of a metal plate used as a workpiece will be explained by FIGS. 10A to 10D , according to the present embodiment.
  • the figure shown on the left side in each of the processes shown in FIGS. 10A to 10D is a cross-sectional view of the workpiece 54 in the longitudinal direction (left-right direction in the drawing).
  • the figure shown on each right side of FIGS. 10A to 10D corresponds to each cross-sectional view of the positions (C-C), (D-D), (E-E) and (F-F) in the vertically upward and downward directions with respect to the longitudinal direction of the workpiece 54.
  • FIGS. 10A and 10D also show perspective views of the workpiece before and after the formation of the protrusions.
  • a rectangular copper plate made of C1100-1 / 4 series copper and having a thickness of 1.5 mm was used as the workpiece 54.
  • two protrusions were formed by abutting a support die 56 having through-holes 55 at two positions where the protrusions were to be formed on one side surface of the copper plate workpiece 54.
  • two protrusions 58 and 59 were formed on one side surface of the workpiece 54 according to the following processes: (a) inserting the workpiece 54 between the support die 56 having a concave step and the through-holes 55, formed at two places in the filled part on one side of the concave step, and a pressure die 57 , (b) clamping the workpiece 54 with the support die 56 and the pressure die 57, (c) forming the protrusions 58, 59 (the portions shown by the dotted line in the drawing) by pressing each cross section of the outer shape end parts of the workpiece 54 from two directions (two directions indicated by the arrows in a longitudinal direction of the workpiece 54 by press forming using a press forming machine, and undergoing plastic flows of metal toward the two through-holes 55 corresponding to the recessed parts of the support die 5, and (d) removing the pressure die 57, and taking out the workpiece 54 having the formed protrusions 58
  • the press molding machine having cam mechanisms at two places to be pressed was used, wherein the press forming machine is a servo press type one that has a cam slide 21 functioning as a pressing die to perform the pressing by intermittent feed.
  • the press molding was performed under the same pressing conditions as in the first embodiment.
  • the workpiece on which the protrusions 58 and 59 were formed was processed into a desired shape by cutting or polishing. If necessary, the workpiece 54 was further subjected to post-processing such as drilling and cutting.
  • the method for forming protrusions according to the present invention can not only form one or a plurality of solid protrusions with high strength at arbitrary positions, but also enables to manufacture metal parts having various shapes and functions by combining with a conventional process of press extrusion molding, or press pressing molding on a work surface of a pressure die having recessed parts. Examples of a method for manufacturing a metal component by combination of the method for forming protrusions according to the present invention and another processing method will be explained by FIGS. 11A to 11D and FIGS. 12A to 12D described later.
  • FIGS. 11A to 11D illustrate cross-sectional views showing schematic processes of a method for manufacturing a metal component by combining the protrusion forming method of the present invention with the press extrusion molding method.
  • the left side of each drawing illustrates a process of performing the extrusion process by press forming, in which a solid protrusion formed by the protrusion forming method of the present invention is press-formed from the bottom surface of the solid protrusion.
  • the right side of each drawing illustrates a cross-sectional view showing a workpiece of a metal plate observed when the extrusion process is stopped in the middle and the pushing die for extrusion is removed after each of the processes shown in 11B, 11C and 11D.
  • the extrusion processing by the press forming is performed by extruding a metal plate workpiece 61 having a solid protrusion 60 formed by the present invention from the bottom surface of the workpiece 61 that is located at the center of the bottom surface of the solid protrusion 60, using the pushing die for extrusion 62. Furthermore, the extrusion processing is continued to increase the height of the protrusion 60, as shown in FIGS. 11B to 11D .
  • a hollow protrusion 63 formed in a stair shape with different bottom diameters can be obtained, when the extruding process by press forming is suspended after the process shown in FIG. 11B and the pushing die 62 is removed. Further, when suspended after the process shown in FIG. 11C , a truncated cone-shaped hollow protrusion 64 can be obtained, wherein a thickness of the tip at the protrusion is thicker than that of the outer peripheral wall. Furthermore, when the extrusion process is continued until the process shown in FIG. 11D , the highest protrusion can be formed as a hollow protrusion 65.
  • the workpiece 61 having the hollow protrusion 63, 64 or 65 formed in each process is processed into a metal component having a desired shape and size by removing unnecessary parts from the main body of the workpiece 61 by punching or cutting. If necessary, a post-process of cutting or polishing the formed surface or the back surface of the protrusion may be performed either before or after the process of punching or cutting.
  • the protrusion forming method of the present invention by combining the protrusion forming method of the present invention with the press extrusion forming method, it is possible to form protrusions having various shapes and structures from the viewpoint of the strength, function and design of the protrusions.
  • the protrusion forming process and the press extrusion forming process according to the present invention may be performed separately as independent processes, or may be performed as a continuous process by a progressive method or a transfer method.
  • FIGS. 12A to 12D illustrate cross-sectional views showing schematic processes when combined with a molding processing method performed by pressing on a work surface, as an example of combining the protrusion forming method of the present invention with another processing method.
  • a process of the method for manufacturing a metal component according to the present invention comprises: lowering a press die for pressing 68 with a recessed part 67 serving as a female mold for forming a solid protrusion 60, in an arrow direction toward one surface of a workpiece 61, after the metal plate workpiece 61 with the solid protrusion 60 formed by the present invention is supported with a support die 66 (in FIG. 12A ); moving the press die for pressing 68 to the workpiece 61 to press onto one surface thereof ( FIG.
  • FIG. 12B forming a solid protrusion inside the recessed part 67 while thinning the workpiece 61 by pushing a part of the workpiece 61 into the recessed part 67 through a gap between the solid protrusion 60 and the non-penetrating recessed part 67 by pressing
  • FIG. 12C forming a solid protrusion inside the recessed part 67 while thinning the workpiece 61 by pushing a part of the workpiece 61 into the recessed part 67 through a gap between the solid protrusion 60 and the non-penetrating recessed part 67 by pressing
  • FIG. 12D moving the press die 68 for pressing in the upward arrow direction to remove the pressing press die
  • the workpiece 61 having the solid protrusion formed by this manner is processed into a metal component having a desired shape and size by removing unnecessary parts from the main body of the workpiece 61 by punching or cutting. If necessary, post-processing of cutting or polishing of the formed surface or the back surface of the protrusion may be performed either before or after the process of punching or cutting.
  • the method for forming a metal component according to the present invention involves the thinning of the workpiece in formation of the projections
  • the solid protrusions with a higher height or a larger diameter can be formed by combining with the molding process by press pressing on the workpiece surface, as compared with the method of performing the molding process by press pressing alone.
  • the protrusion forming method and the molding method by press pressing according to the present invention may be separately performed as independent processes, or may be performed as a continuous process by a progressive method or a transfer method.
  • the method for forming protrusions according to the present invention can easily form the solid protrusions on the workpiece of the metal plate or the metal rod without making the metal plate thinner, or without deforming the metal rod or reducing the diameter thereof.
  • the solid protrusion can be formed in the shape with a higher height than the thickness of the metal plate or the diameter of the metal rod, which is used as the workpiece. Since the solid protrusions formed by the method for forming protrusions according to the present invention have high uniformity and strength at the same time, not only high quality protrusions can be obtained, but also two or more protrusions can be formed at a desired position of the workpiece.
  • the protrusions can be formed not only in the direction perpendicular to one surface of the metal workpiece but also in an oblique direction, and the shape of the protrusions can be not only conical but also pyramidal. This results in a wide selection of directions (angles) and the protrusion shapes when forming the protrusions.
  • the method for manufacturing a metal component according to the present invention can provide metal components with various shapes and functions by combining with the conventional press extrusion forming method, or the conventional forming method by press pressing, in which the pressure die having the recessed part is pressed onto the workpiece surface. It is therefore possible to provide metal components having various shapes and functions.
  • the method for manufacturing a metal component according to the present invention can expand its application area not only to general-purpose metal parts but also to precision metal parts.

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EP19810837.5A 2018-05-31 2019-05-29 Verfahren zur herstellung eines vorsprungteils, system zur herstellung eines vorsprungteils und verfahren zur herstellung einer metallkomponente mit dem vorsprungteil Active EP3812061B1 (de)

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JP2017094341A (ja) * 2015-11-18 2017-06-01 株式会社神戸製鋼所 プレス成形品の製造方法及びプレス成形装置
JP6550322B2 (ja) * 2015-11-18 2019-07-24 株式会社神戸製鋼所 プレス成形品の製造方法及びプレス成形装置
CN105921657B (zh) * 2016-07-15 2018-06-29 合肥工业大学 制备难熔金属超细晶材料的闭塞式背压双向镦挤成形方法

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KR102480849B1 (ko) 2022-12-22
CN112236245B (zh) 2023-04-28
US11931787B2 (en) 2024-03-19
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TW202003131A (zh) 2020-01-16
CN112236245A (zh) 2021-01-15
US20210213509A1 (en) 2021-07-15
US20230201902A1 (en) 2023-06-29
US11648599B2 (en) 2023-05-16
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EP3812061A4 (de) 2022-03-09
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